FUEL INJECTOR REMOVAL


  1. PRECAUTION (w/ Navigation System for HDD)

    Note

    After the power switch is turned off, the navigation receiver assembly (HDD navigation system) records various types of memory and settings. As a result, after turning the power switch off, make sure to wait at least 60 seconds before disconnecting the cable from the negative (-) auxiliary battery terminal.

  2. DISCHARGE FUEL SYSTEM PRESSURE

    Click here

  3. REMOVE REAR NO. 2 FLOOR BOARD


    1. A01JB5ZE01

      Disengage the 2 guides <A> as shown in the illustration.

    2. Disengage the 3 guides <B> and remove the rear No. 2 floor board.

  4. REMOVE REAR DECK FLOOR BOX


    1. Remove the rear deck floor box.

  5. REMOVE REAR NO. 3 FLOOR BOARD


    1. A01JC33

      Disengage the 2 guides and remove the rear No. 3 floor board.

  6. DISCONNECT CABLE FROM NEGATIVE AUXILIARY BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  7. REMOVE NO. 2 CYLINDER HEAD COVER (w/o EGR System)


    1. A01JAJ9

      Remove the 3 clips and No. 2 cylinder head cover.

      Note


      • Attempting to disengage both front and rear clips at the same time may cause the cover to break.

      • Pull the cover straight up to remove. Attempting to pull the cover forward may cause it to break.

      Note

      Attempting to disengage both front and rear clips at the same time may cause the cover to break.

  8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY (w/o EGR System)


    1. A01JAMH

      Disconnect the connector.

    2. A01J9I2

      Loosen the hose clamp and disconnect the air cleaner hose assembly.

    3. Remove the 2 clamps and air cleaner cap sub-assembly.

  9. REMOVE INLET AIR CLEANER ASSEMBLY (w/o EGR System)


    1. A01JBRT

      Remove the 2 bolts and inlet air cleaner assembly.

  10. REMOVE AIR CLEANER CASE (w/o EGR System)


    1. A01JAKM

      Separate the No. 4 water by-pass hose from the air cleaner case.

    2. Remove the 3 bolts and air cleaner case.

  11. REMOVE AIR CLEANER HOSE ASSEMBLY (w/o EGR System)


    1. A01JCDC

      Disconnect the ventilation hose from the cylinder head cover sub-assembly.

    2. Loosen the hose clamp and remove the air cleaner hose assembly.

  12. REMOVE EGR WITH COOLER PIPE SUB-ASSEMBLY (w/ EGR System)

    Click here

  13. DISCONNECT ENGINE WIRE


    1. A01JAIL

      Disconnect the 4 fuel injector connectors.

    2. Disconnect the 4 connectors.

    3. Remove the bolt.

    4. Disengage the 2 clamps to disconnect the engine wire.

  14. DISCONNECT FUEL TUBE SUB-ASSEMBLY


    1. A01JA65

      Release the claw and remove the No. 1 fuel pipe clamp.

    2. A01JD3SE01

      Pinch the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

      Note


      • Check for foreign matter on the fuel tube sub-assembly around the fuel tube connector. Clean it if necessary. Foreign matter can affect the ability of the O-ring to seal the fuel tube connector and fuel pipe.

      • Do not use any tools to separate the fuel tube connector and fuel pipe.

      • Do not forcibly bend, kink or twist the fuel tube sub-assembly.

      • Keep the fuel tube connector and fuel pipe free from foreign matter.

      • If the fuel tube connector and fuel pipe are stuck together, pinch the fuel tube connector and turn it carefully to disconnect it.

      • Cover the fuel tube connector with a plastic bag to prevent damage and contamination.

  15. SEPARATE NO. 1 WATER BY-PASS PIPE (w/o EGR System)


    1. A01JAFY

      Disengage the clamp to disconnect the engine wire.

    2. Remove the 2 bolts and nut, and separate the No. 1 water by-pass pipe.

  16. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01JC1X

      Remove the bolt.

    2. A01J9MR

      Remove the 2 bolts and the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Be careful not to drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

  17. REMOVE NO. 1 DELIVERY PIPE SPACER


    1. A01JCSY

      Remove the 2 No. 1 delivery pipe spacers from the cylinder head.

  18. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01JBO3

      Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

    2. Remove the O-ring from each fuel injector assembly.

    3. For reinstallation, attach a tag or label with the corresponding cylinder number to each fuel injector shaft.

      Note

      Protect the fuel injector assemblies by covering them with plastic bags.

    4. A01JC7S

      Remove the 4 injector vibration insulators.